Magnetic conveyor belt module

ABSTRACT

A magnetic conveyor belt module integrates a magnetic element into the body of the module to attract conveyed articles to the body. The magnetic conveyor belt module includes a recess for seating a magnetic element and a retention element for retaining the magnetic element within the recess. A cover encapsulates the magnetic element within the body of the module.

BACKGROUND OF THE INVENTION

The invention relates generally to power-driven conveyors and moreparticularly to modular plastic conveyor belts with metal-attracting orferro-magnetic properties.

Conveyors are often used to transport items. To convey metal ormagnetically attractable items, such as bakery pans, conveyors have beenused that include magnetic elements to retain themagnetically-attractive items on the conveyor. Integrating the magneticelements into the conveyor may be cumbersome.

Modular plastic conveyor belts are widely used in various industries toconvey products. Modular plastic conveyor belts are constructed of aseries of rows of side-by-side belt modules. Hinge eyes along oppositeends of each row interleave with hinge eyes of consecutive rows. A hingerod inserted in the interleaved hinge eyes connects the rows together athinge joints into an endless conveyor belt loop.

SUMMARY OF THE INVENTION

A magnetic conveyor belt module comprises a main body, a magneticelement and a carrier for a magnetic element coupled to the main body.The module allows a magnetic element to be easily and removablyintegrated with the module. A magnetic element is seated in a recessnear the top surface of the module body. A cover covers the magneticelement. A retention element retains the cover and magnetic element inplace.

According to one aspect, a conveyor belt module comprises a module body,a first set of hinge elements spaced apart across gaps along the firstend of the module body, a second set of hinge elements spaced apartacross gaps along the second end of the module body, a slot formed inthe upper surface of the module body and extending from a first edgetowards a second edge of the module body. The module also includes aninsert containing a magnetic element inserted into the slot.

According to another aspect, a conveyor belt module comprises a modulebody, first and second sets of hinge elements, a magnetic elementcoupled to the module body and a retaining element for retaining themagnetic element in a general position relative to the module body.

According to another aspect, a magnetic conveyor belt module comprises amodule body, first and second sets of hinge elements, a recess in a topsurface of the module body, a magnetic bar seated in the recess and acover covering the recess and encapsulating the magnetic bar. The coverhas a top surface that is substantially flush with the top surface ofthe module body.

BRIEF DESCRIPTION OF THE DRAWINGS

These features and aspects of the invention, as well as its advantages,are better understood by referring to the following description,appended claims, and accompanying drawings, in which:

FIG. 1 is an exploded view of a magnetic conveyor belt module accordingto an illustrative embodiment of the invention;

FIG. 2 is a top view of the magnetic conveyor belt module of FIG. 1 whenassembled;

FIG. 3 is a cross-sectional view of the magnetic conveyor belt modulethrough lines A-A of FIG. 2;

FIG. 4 is a cross-sectional view of the magnetic conveyor belt modulethrough lines B-B of FIG. 2;

FIG. 5 is a cross-sectional view of the magnetic conveyor belt modulethrough lines C-C of FIG. 2;

FIG. 6 is a bottom view of the magnet-carrying insert of the magneticconveyor belt module;

FIG. 7 is an exploded view of another embodiment of a magnetic conveyorbelt module;

FIG. 8 is a top view of the magnetic conveyor belt module of FIG. 7;

FIG. 9 is a cross-sectional view of the magnetic conveyor belt module ofFIG. 8 through lines A-A;

FIG. 10 is a cross-sectional view of the magnetic conveyor belt moduleof FIG. 8 through lines B-B;

FIG. 11 is an isometric view of a magnetic conveyor belt module duringformation according to another embodiment of the invention;

FIG. 12 is a top view of the magnetic conveyor belt module of FIG. 11after overmolding of a cover for the magnetic element;

FIG. 13 is a cross-sectional view through lines A-A in FIG. 12;

FIG. 14 is an exploded, isometric view of a magnetic conveyor moduleaccording to another embodiment of the invention;

FIG. 15 is a top view of the module of FIG. 14;

FIG. 16 is a cross-sectional view of the magnetic conveyor belt moduleof FIG. 14 through lines A-A;

FIG. 17 is a cross-sectional view of the magnetic conveyor belt moduleof FIG. 14 through lines B-B;

FIG. 18 is a bottom view of the cover of the magnetic conveyor beltmodule of FIG. 14;

FIG. 19 is an exploded view of a magnetic conveyor belt module accordingto another embodiment of the invention;

FIG. 20 is a top view of the assembled magnetic conveyor belt module ofFIG. 19;

FIG. 21 is an edge view of the assembled magnetic conveyor belt moduleof FIG. 19;

FIG. 22 is a side view of the assembled magnetic conveyor belt of FIG.19;

FIG. 23 is a top view of the magnet-carrying insert of the magneticconveyor belt module of FIG. 19;

FIG. 24 is an end view of the magnet-carrying insert of the magneticconveyor belt module of FIG. 19;

FIG. 25 is a side view of the magnet-carrying insert of the magneticconveyor belt module of FIG. 19; and

FIG. 26 is a bottom view of the magnet-carrying insert of the magneticconveyor belt module of FIG. 19.

DETAILED DESCRIPTION OF THE INVENTION

A conveyor belt module integrates a magnetic element to attract conveyedarticles against the conveying surface of the module. The invention willbe described below relative to certain illustrative embodiments, thoughthose skilled in the art will recognize that the invention is notlimited to the described embodiments.

Referring to FIGS. 1-6, a conveyor belt module 10 for a conveyor beltincludes a module body 12 that extends longitudinally from a first end14 to a second end 15. The longitudinal direction is the direction ofbelt travel when such a module is built into a modular conveyor belt.The module body extends laterally from a first edge 16 to a second edge17. In thickness, the module body extends from an upper surface 18,which forms the conveying surface on which conveyed articles arecarried, to an opposite surface 19. Hinge structure, shown as eyes 20,extends longitudinally outward from the first and second ends of themodule body. The tops of the hinge eyes form a continuation of theconveying surface. The hinge eyes on one end of the module body arelaterally offset from the hinge eyes at the other end. Gaps 26 betweenlaterally consecutive hinge eyes are sized to receive the hinge eyes ofsimilar modules in an adjacent row of modules in a conveyor belt.

The modules are preferably made of thermoplastic polymers, such aspolypropylene, polyethylene, acetal, or composite polymers in aninjection-molding process. Plastic conveyor belt modules made in thisway are available commercially from Intralox, L.L.C., of Harahan, La.,USA. In another embodiment, the modules are formed of stainless steel oranother suitable material.

A number of modules 10 are used to form a conveyor belt. The belt maycomprise a series of rows of edge-to-edge belt modules. Modules ofdifferent lateral widths are used to construct the belt in a bricklaypattern. But wide modules extending the entire width of the belt couldalternatively be used. The belt may comprise a combination of magneticand non-magnetic modules. The rows are interconnected by hinge rods 22extending laterally through the passageways formed by the alignedopenings in the interleaved hinge eyes between adjacent rows. The beltconveys articles atop the conveying surfaces 18 of the modules along anupper carryway portion of the conveyor. The belt is trained aroundsprockets mounted on each end of the carryway, and returns along areturnway below the carryway.

The magnetic module 10 includes a recess, illustrated as a slot 50, inthe upper surface 10 for receiving a magnetic insert. The illustrativeslot 50 extends from the first edge 16 to an intermediate locationwithin the body, and is open to the side of the module. The illustrativeslot 50 slidably receives a magnetic insert 70 housing a magnet 80. Inanother embodiment, the recess has another shape other than a slot.

The slot has chamfered sides 51, 52 that angle inwards and a rounded end53. The insert 70 has a rounded tip 73 complementary to the rounded end53 and chamfered or tapering sides 71, 72 to form a substantiallytrapezoidal cross-section. The insert 70 includes a recess 74 or pocketfor receiving a magnetic element, illustrated as a rectangular magneticbar 80, though the invention is not so limited. When assembled, theupper surface of the insert 70 is flush with the upper surface of themodule body 12 to form a substantially continuous surface. The insert 70covers and encapsulates the magnetic bar 80.

The module further includes a retention element for retaining themagnetic insert 70 within the module body. According to an illustrativeembodiment of the invention, the insert interacts with a hinge rodretaining element 90 to retain the insert within the module body.

The illustrative rod retaining element 90 comprises a movable shuttleplug, such as the shuttle plugs describe in U.S. Pat. No. 5,904,241 andU.S. Pat. No. 6,814,223, which are incorporated herein by references, orthe retaining elements U.S. Pat. No. 6,857,516 and U.S. Pat. No.7,255,227, the contents of which are incorporated herein by reference.

The illustrative shuttle plug 90 is inserted in a passageway 91 in themodule body and into an edge hinge element 20 a for retaining a rod 22within a hinge passageway. The shuttle plug includes a detent 93 thatextends through an opening, shown as a channel 59, in the floor of themodule body slot 50. The detent engages a recess, shown as a channel 78,in the insert 70 to retain the insert within the module body. Theopening 59 and recess 78 allow the shuttle plug 90 to slide within thepassageway 91 while still engaging the recess of the insert 70.

The magnetic bar 80 is preferably centered on the module body, as shownin FIG. 5.

The use of a slot, insert and automatic locking mechanism facilitatesintegration of an article-attracting element, such as a magnet, into theconveyor belt module.

In another embodiment, shown in FIG. 7-10, a magnetic element issandwiched between elements in the module. The module 110 comprises abase member 120, a top cover 150 and a magnet 180 or magnetic elementsandwiched between the top cover and base member. The base member has arecess 122 for receiving the top cover 150. When received in the recess122, the top cover upper surface is flush with the upper surface of thebase member 120, as shown in FIG. 9, and encapsulates the magnet 180.The module includes openings 126 within the hinge elements 124 forreceiving hinge elements 154 on the top cover 150. The base hingeelements 124 sandwich the top cover hinge elements 154. One or morehinge rods 160 form a retention element for retaining the top cover onthe base member. The base member and/or the top cover may include apocket 171 for accommodating the magnet 180. The pocket 171 is sized andshaped to seat the magnet 180. The illustrative module further includesa shuttle plug 190 for retaining the hinge rods within the hinge rodpassageway.

FIGS. 11-13 show another embodiment of a magnetic conveyor belt module210. The conveyor belt module 210 integrates a magnetic element 280 intothe module during a secondary molding process. A base member 220, formedduring an initial mold includes a recess or pocket 271 for receiving amagnetic element 280. The recess or pocket 271 includes guide pads 272,273 for positioning the magnetic element 280. After positioning themagnetic element 280 in the recess or pocket 271, a cover 250 isovermolded onto the module to encapsulate the magnetic element 280. Thebase member 220 includes two passageways 221, 222 extending down fromthe recess 271 for creating solid protrusions 255, 256 anchoring theovermolded cover 250 to the base member 220. The overmolded cover 250preferably has a top surface that is flush with the top surface of thebase member 220, as shown in FIG. 13.

In one embodiment, the magnetic element 280 comprises a samarium cobaltmagnet, allowing the magnet the ability to maintain the ability toattract after undergoing the high temp overmolding process.

In another embodiment of the invention, shown in FIGS. 14-18, a cover350 for covering a magnetic element 380 may be ultrasonically welded toa base member 320 to form a magnetic conveyor belt module 300. Themagnetic element 380 is positioned within a recess or pocket 371 in theupper surface of the base member 320. The recess or pocket 371 includesa deeper recess 372 configured to receive and position the magneticelement 380. The cover 350, as shown in FIG. 18, includes weld joints352 for ultrasonically welding the cover to the base member 322 toencapsulate the magnetic element 380 within the body of the module. Thecover also includes a recess 353 for receiving the top portion of themagnetic element 380. When assembled, the magnetic conveyor belt moduleintegrates the magnetic element 380 into the body while providing asubstantially continuous upper conveying surface 311.

FIGS. 19-26 show a magnetic conveyor belt module 400 according toanother embodiment of the invention. The magnetic conveyor belt moduleincludes a module body 412 having hinge elements 420 and a recess, shownas a slot 450, for receiving a magnetic insert 470 housing a magnet 480.The magnetic conveyor belt module 400 is similar to the embodiment shownin FIGS. 1-6, with the addition of an insert retainer that engages therod retaining element 490 when the module is fully assembled. Theillustrative insert retainer comprises first and second protrusions 475,476 on the bottom surface of the insert 470 for engaging recesses 462,464 in the module body.

The illustrative magnetic insert 470 includes a rounded tip that fitsinto a rounded end 453 of the slot 450.

The module includes a shuttle plug 490 inserted in a passageway 491 inthe module body and into an edge hinge element for retaining a rod 494within a hinge passageway. The shuttle plug includes a detent 493 thatextends through an opening or abuts a side edge 459 in the floor of themodule body slot 50. The detent engages a recess, shown as a channel478, in the insert 470 to retain the insert within the module body. Theopening 459 and channel 478 allow the shuttle plug 490 to slide withinthe passageway 491 while still engaging the recess of the insert 470.The channel 478 is between the first and second protrusions 475, 476 onthe insert. When the front protrusion 479 is locked in the recess 462,the second protrusion fits in the rear recess 464 and locks the detent493 of the shuttle plug within the passageway.

The illustrative first protrusion 475 on the insert includes a slopedfront face 479 to facilitate insertion and locking of the insert 470.

As shown in FIG. 24, the insert 470 includes a base portion 471 and anoverhanging upper portion 472. The base portion 471 includes slopingsides, though the invention is not so limited. The upper portionincludes a flat top surface and tapering edges 473, 474.

In another embodiment a cover for retaining a magnet relative to amodule body can be glued or otherwise attached to the module body.

Though the illustrative embodiments show the magnet as covered, theinvention is not so limited. For example, the magnetic element can bepartially or fully exposed. The magnetic element may be at or near thetop surface of the module, or inset from the top surface.

The invention is also not limited to the illustrative magnetic bar. Themagnetic element can have any suitable size, shape, position andorientation.

In another embodiment of the invention, the module comprisesmagnetizable material that is added during formation of the module usinginjection molding. The magnetizable material can be magnetized withinthe mold to incorporate a magnetic element into the conveyor beltmodule. In one embodiment, a cover may be molded from a magnetizableplastic, and then inserted into or overmolded onto a module body. Themagnetizable plastic may then be magnetized to integrate a magneticelement to a conveyor belt module.

Although the invention has been described in detail with reference to afew exemplary versions, other versions are possible. The scope of theclaims is not meant to be limited to the versions described in detail.

What is claimed is:
 1. A conveyor belt module comprising: a module bodyextending longitudinally in the direction of belt travel from a firstend to a second end, laterally from a first edge to a second edge and inthickness from a top surface to an opposite bottom surface; a first setof hinge elements spaced apart across first gaps along the first end; asecond set of hinge elements spaced apart across second gaps along thesecond end; a slot formed in and open to the upper surface and extendingfrom the first edge towards the second edge, wherein the slot is open tothe first edge and includes an opening to a passageway in the modulebody below the slot; an insert inserted into the slot, the insertincluding a magnetic element and a channel on a bottom surface of theinsert; and a rod retention element inserted in the passageway forretaining a hinge rod, wherein the rod retention element includes adetent passing through the opening that engages the channel on thebottom surface of the insert to retain the insert in the slot.
 2. Themodule of claim 1, wherein the slot includes chamfered edges.
 3. Themodule of claim 1, wherein the insert includes chamfered edges.
 4. Themodule of claim 1, wherein the slot and insert have a rounded tip. 5.The module of claim 1, wherein the magnetic element comprises a magneticbar inserted in a recess of the insert.
 6. The module of claim 1,wherein the module and insert are formed of plastic.
 7. The module ofclaim 1, wherein the insert includes a ramped protrusion on a bottomsurface for insertion in a recess on the module body.
 8. The module ofclaim 7, wherein the insert further includes a second protrusion on thebottom surface adjacent to an end of the insert and the channel.
 9. Aconveyor belt module comprising: a module body extending longitudinallyin the direction of belt travel from a first end to a second end,laterally from a first edge to a second edge and in thickness from a topsurface to an opposite bottom surface; a first set of hinge elementsspaced apart across first gaps along the first end; a second set ofhinge elements spaced apart across second gaps along the second end; anelongated insert including a magnetic element coupled to the modulebody, the elongated insert having a channel formed on a bottom surfacethereof; and a retaining element comprising a shuttle plug inserted in apassageway of the module body and in communication with one of the hingeelements, the retaining element including a detent that cooperates withthe channel on the elongated insert to retain the magnetic element in ageneral position relative to the module body.
 10. The conveyor beltmodule of claim 9, wherein the magnetic element is sandwiched betweenthe module body and a top cover coupled to the module body.
 11. Amagnetic conveyor belt module, comprising: a module body extendinglongitudinally in the direction of belt travel from a first end to asecond end, laterally from a first edge to a second edge and inthickness from a top surface to an opposite bottom surface; a first setof hinge elements spaced apart across first gaps along the first end; asecond set of hinge elements spaced apart across second gaps along thesecond end; a slot formed in the top surface of the module body and opento the first edge of the module body, the slot including a first recessand a second recess in a bottom surface thereof; a magnetic bar seatedin the slot; and a cover covering the slot and encapsulating themagnetic bar, wherein the cover has a first protrusion that mates withthe first recess and a second protrusion that mates with the secondrecess.
 12. The magnetic conveyor belt module of claim 11, wherein theslot extends from the first edge towards the second edge.
 13. Themagnetic conveyor belt module of claim 11, wherein the cover isultrasonically welded to the module body.
 14. The magnetic conveyor beltmodule of claim 11, wherein the slot includes guide pads for positioningthe magnetic bar.
 15. The magnetic conveyor belt module of claim 11,wherein the first protrusion has a sloped front face.
 16. The magneticconveyor belt module of claim 11, wherein the slot has an openingbetween the first recess and the second recess that is open to apassageway in the module body.
 17. The magnetic conveyor belt module ofclaim 16, wherein the cover further includes a channel between the firstprotrusion and the second protrusion.
 18. The magnetic conveyor beltmodule of claim 17, further comprising a shuttle plug inserted in thepassageway and having a detent configured to engage the channel in thecover.